N. Dust Control.pdf

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Dust Contro l

Indonesia Customer Seminar

June 13 & 14 2012

Jakarta Indonesia



Dust Control Applications



Typical Coal Handling Facility



Dust Control- Key Programs for Power

DustFoamPlus Wet surfactant spray

@ 1:2000 dilution

Applied @ transfer points

between rail/truck dump

and stockpile

DustFoamPlus Foam residual dust

suppression;

normally applied

after reclaim

Applied after reclaim @

crushers, transfer points,

tripper deck

Dust-Ban 7977 Prevents windage,

erosion loss on

storage pile

Treatment lasts 30 days

DustBind Inactive coal pile

crusting agent

3 step application per CPP;

lasts 4 mos. or longer

Haul-E-Z 81201 Residual road dust

control

Also used as belt de-icer,

coal pile freeze protection;

green product, non-glycol



DustFoam, DustFoamPlus

Minimal BTU penalty (< 0.5%moisture addition)

Residual dust control

> 80% airborne dust reduction isachievable

Biodegradable

Maximum expansion ratio

Highly effective on PRB

Before DustFoam

After DustFoam



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Typical Foam System Layout

Electrical

Auto/Switch

DustFoamPlus

Control

Module

Expansion

Chamber

Chemical Plant Water

Plant Air

Solution (Water /Chemical)

Plant Air

Material and/or Motion Sensor

IMPORTANT

TOTAL HOSE

LENGTHS FROM

EXPANSION

CHAMBER TOSPRAY NOZZLES

MUST BE 30 FT

OR LESS.

ALL HOSES MUST

BE IDENTICAL IN

DIAMETER &

LENGTH.



Model DF20S Standard Control Module

• Mounted in a 42”x 36”NEMA 4 dust tight Cabinet. • 20 GPM water driven dosing pump.

• Air, water and solution lines, check valves.

• Air/water Pressure regulators, gauges and Flow meters.

• Air/solution Flow control ball valves with air actuators.

• 2” 100 mesh water strainer and 200 mesh filter.

• Purge system for freeze protection.

Electric control options

Model DFCP- PL Logic control panel for ‘auto’ on/off operation. • 120 VAC ‘PLC’ controls mounted in a 16”x 14” NEMA 4X Cabinet.

(or)

Model DFCP-S ‘Standard Relay panel for ‘auto’ on/off operation. • 120 VAC standard relay controls mounted in a 16”x 14” NEMA 4X

Cabinet.

Expansion Chambers• 24”x 6”, 30”x 6” or 40”x 6” (depending upon required foam output)

expansion chamber with top and bottom fittings, control valves, gauges

and up to 6 foam outlets.

Standard 800 TPH Foam System



Excellent „dry‟ stable micro bubble structured Foam



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Excellent ‘dry’ stable micro bubble structured foam sprays



‘Inefficient’ poor large bubble structured Foam



DustFoam Spray to Head Box



Radial Stackout With and Without DustFoam



Wet Suppression @ Rotary Car Dump



Dust Monitoring Equipment



Monitoring Results With & Without DustFoam

2A Feeders W/O Dustfoam

0

1

2

3

4

5

6

7

8

0 8 : 3 2 : 1 2

0 8 : 4 5 : 1 2

0 8 : 5 8 : 1 2

0 9 : 1 1 : 1 2

0 9 : 2 4 : 1 2

0 9 : 3 7 : 1 2

0 9 : 5 0 : 1 2

1 0 : 0 3 : 1 2

1 0 : 1 6 : 1 2

1 0 : 2 9 : 1 2

1 0 : 4 2 : 1 2

1 0 : 5 5 : 1 2

1 1 : 0 8 : 1 2

1 1 : 2 1 : 1 2

1 1 : 3 4 : 1 2

1 1 : 4 7 : 1 2

1 2 : 0 0 : 1 2

1 2 : 1 3 : 1 2

1 2 : 2 6 : 1 2

1 2 : 3 9 : 1 2

1 2 : 5 2 : 1 2

1 3 : 0 5 : 1 2

1 3 : 1 8 : 1 2

1 3 : 3 1 : 1 2

1 3 : 4 4 : 1 2

1 3 : 5 7 : 1 2

1 4 : 1 0 : 1 2

1 4 : 2 3 : 1 2

1 4 : 3 6 : 1 2

1 4 : 4 9 : 1 2

1 5 : 0 2 : 1 2

1 5 : 1 5 : 1 2

1 5 : 2 8 : 1 2

1 5 : 4 1 : 1 2

1 5 : 5 4 : 1 2

1 6 : 0 7 : 1 2

1 6 : 2 0 : 1 2

m g / m 3 Avg. 1.37 mg/m3

Max. 12.9 mg/m3

2A Feeders With Dustfoam

00.20.40.60.81

1.21.41.61.8

2

0 9 : 5 1 : 1 2

0 9 : 5 8 : 1 2

1 0 : 0 5 : 1 2

1 0 : 1 2 : 1 2

1 0 : 1 9 : 1 2

1 0 : 2 6 : 1 2

1 0 : 3 3 : 1 2

1 0 : 4 0 : 1 2

1 0 : 4 7 : 1 2

1 0 : 5 4 : 1 2

1 1 : 0 1 : 1 2

1 1 : 0 8 : 1 2

1 1 : 1 5 : 1 2

1 1 : 2 2 : 1 2

1 1 : 2 9 : 1 2

1 1 : 3 6 : 1 2

1 1 : 4 3 : 1 2

1 1 : 5 0 : 1 2

1 1 : 5 7 : 1 2

1 2 : 0 4 : 1 2

1 2 : 1 1 : 1 2

1 2 : 1 8 : 1 2

1 2 : 2 5 : 1 2

1 2 : 3 2 : 1 2

1 2 : 3 9 : 1 2

1 2 : 4 6 : 1 2

1 2 : 5 3 : 1 2

1 3 : 0 0 : 1 2

1 3 : 0 7 : 1 2

1 3 : 1 4 : 1 2

1 3 : 2 1 : 1 2

1 3 : 2 8 : 1 2

1 3 : 3 5 : 1 2

1 3 : 4 2 : 1 2

1 3 : 4 9 : 1 2

1 3 : 5 6 : 1 2

m g

/ m 3

Average 0.188 mg/m3

Maximum 2.7 mg/m3

(Vibratory feeders under reclaim pile)



Live Storage With & Without DustFoam



Filling Water Truck for DustBind Application



Spraying Pile With DustBind Solution



Spraying DustBind With Water Cannon



DustBind Surface



Dust Control

Rule of Thumb: 1 spray or foam application (at transferpoint) for each 500 tons/hr coal flow; e.g., if 600 tons/hrcoal flow, 2 application points are required

Off-the shelf foam equipment supplied by Viking Equipt.,Inc.

CPPs for the various dust control products containdetailed application instructions

A 500 MW unit burns 230 tons/hr bituminous coal, hr,

i.e., 0.460 tons/MW



Freeze Conditioning Agent (FCA)

Eliminice 8882 Belt Deicer (can be used as haul road

dust control agent also)

Nalco‟s patented glycerin-based FCA; a very unique“green” product

Other commodity-type FCA have big drawbacks: Glycol FCA products are very toxic

Calcium chloride is corrosive to coal handling equipment andboiler internals

Nalco 8880 used for coal load-out, side release agent incoal rail cars, etc.

FCA spray equipment systems available from VikingEquip. or Boggs Municipal Services Co.



Problem Locations for Wet Coal



Wet Coal Flow Additive

Coal feeder

Injection

nozzle assy



Case study: Wet Coal Flow Additive

165 pulverized coal-fired unit (PRB coal)

Wet coal plugs between the coal feeder(s) and thepulverizers

DustCon injected as neat product into downcomer chute@ 0.25-0.50 pints/ton

Use standard feed skid (part no. IM1A02A0.88) withhollow cone nozzle assy

Best results when fed intermittently; 15 min. to onefeeder, then 15 min. to the next, etc. (4 feeders total)

Coat inside surface of downcomer chute

Treatment prevents loss of 1 feeder, 25% of total coalfeed to boiler



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